Sizing additives for drycleaning processes

ABSTRACT

A fabric treatment composition including a sizing agent and a silicone solvent is provided. The sizing agent is a hydrogenated rosin ester. The silicone solvent is a volatile silicone solvent. Optionally, co-solvents and dispersing agents may be included. A method of treating a fabric article and the treated fabric article are provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of and priority to prior filed and U.S.Provisional Patent Application Ser. No. 61/501,612 entitled “SIZINGADDITIVES FOR DRYCLEANING PROCESSES,” filed on Jun. 27, 2011, which isexpressly incorporated by reference herein in its entirety.

FIELD OF USE

This invention relates to dry cleaning compositions and methods thatprovide sizing and body to articles and garments.

BACKGROUND

The majority of drycleaners today clean with the solventperchloroethylene, also known as tetrachloroethylene or “PERC”. PERC hasbeen in common use since the 1940's and it is very effective in removingsoils from garments that must be drycleaned. PERC is non-flammable,easily purified by distillation, and does not easily break down to formcorrosive agents. Additionally, PERC does not contribute to theformation of smog.

Despite the foregoing, there has been a movement to replace PERC in thedry cleaning industry. One class of solvents that has evolved as aPERC-replacement in the dry cleaning industry is silicone solvents, suchas straight chain and cyclic silicones. Silicone solvents have been usedfor decades in products such as cosmetics, deodorants, skinpreparations, bath oils, suntan preparations, shaving products and hairproducts, and are characterized as possessing favorable properties suchas low-odor and low-surface tension. Additionally, silicone solvents arenon-greasy, non-toxic (oral, dermal, inhalation), non-irritating,non-sensitizing, and have no immunosuppressant effects.

One exemplary silicone solvent is decamethylcyclopentasiloxane, which isalso known as D5 cyclomethicone and exhibits ideal properties for adrycleaning fluid. See U.S. Pat. No. 6,063,135 issued on May 16, 2000,which is hereby incorporated by reference in its entirety.Decamethylcyclopentasiloxane has a high flashpoint at 170° F., distillseasily in a vacuum still, has anti-dye bleeding properties, is staticfree, safe on all fabrics and resists wrinkling. However, one of themain complaints of silicone fluid cleaned garments is that the cleanedfabrics have a limp hand with no body. To address the poor hand,drycleaners add sizing additives to the solvent to add body and to aidin retaining creases. The sizing additives are typically thermoplastichydrocarbon resins derived from natural terpene hydrocarbons orpetroleum sources. Unfortunately, these resins are not soluble indecamethylcyclopentasiloxane dry cleaning fluid.

Therefore, a need exists for new sizing agents that are soluble insilicone solvents.

SUMMARY

According to an embodiment of the invention, a fabric treatmentcomposition is provided. The composition includes a sizing agent and asilicone solvent, where the sizing agent includes a hydrogenated rosinester.

According to another embodiment of the invention, a method for applyinga fabric treatment composition to a fabric article in a dry cleaningappliance is provided. The method includes the steps of (a) dispensing afabric treatment composition into the treatment chamber, wherein fabrictreatment composition includes a sizing agent comprising a hydrogenatedrosin ester, and (b) contacting the fabric article with the fabrictreatment composition.

According to yet another embodiment of the invention, a treated fabricarticle is provided. The treated fabric article includes a fabricarticle having a residue of a sizing agent thereon. The sizing agentincludes a hydrogenated rosin ester.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with the brief description given above and a detaileddescription of the embodiments given below, serve to explain theprinciples of the embodiments of the invention.

FIG. 1 illustrates a method of treating a fabric article to provide atreated fabric article, in accordance with an embodiment of the presentinvention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As commonly done in aqueous systems, sizing agents are generally appliedto fabric articles as dilute solutions. Sizing agents impart improvedphysical properties, such as crease retention, to a fabric article.Moreover, the sizing agents can also improve the “hand” of the fabricarticle, i.e., improve the tactile qualities such as softness, firmness,elasticity, fineness, resilience and other qualities perceived by touch.The sizing agents of embodiments of the present invention are compatiblewith non-aqueous dry cleaning systems, which utilize a silicone solventas the carrier medium.

Thus, according to embodiments of the invention, a fabric treatmentcomposition is provided, the composition including a sizing agent and asilicone solvent. Moreover, a method for applying the fabric treatmentcomposition to a fabric article in a dry cleaning appliance includes thesteps of: (a) dispensing a fabric treatment composition into thetreatment chamber, wherein fabric treatment composition includes asizing agent comprising a hydrogenated rosin ester; and (b) contactingthe fabric article with the fabric treatment composition. In alternativeembodiments, the method may further include placing the fabric articleinto the drying cleaning appliance, providing a concentrated mixture ofthe fabric treatment composition, diluting the concentrated mixture withan additional amount of the silicone solvent to form an operativemixture of the fabric treatment composition, evaporating at least aportion of the solvent after the contacting step to thereby provide thefabric article with at least a portion of the sizing agent retainedthereon, and/or combinations thereof.

In an embodiment, the fabric treatment composition is added to the drycleaning appliance after a wash process step. Accordingly, thedrycleaning appliance may be charged with a fabric article and acleaning solution comprising a detergent, where the fabric article iscontacted by the cleaning solution for a suitable duration (e.g., about5 to about 20 minutes). If desired, a portion of the cleaning solutionmay be removed from the drycleaning appliance after the wash processstep and prior to introducing the fabric treatment composition to thedrycleaning appliance. Removal of a portion of the cleaning solutionreduces the dilution effect on the fabric treatment composition, therebyproviding a more concentrated solution of sizing agent during thetreatment step.

According to various embodiments of the invention, the contactingduration varies depending on the cleaning needs and generally for a timeeffective to substantially clean the fabric and provide the desiredsizing effect. For example, the contacting duration may range from lessthan about 1 minute to about 20 minutes, from about 1 minute to about 15minutes, from about 3 minutes to about 10 minutes, or about 2 minutes toabout 5 minutes, for example. After the contacting period, a portion ofthe fabric treatment composition may be separated from the fabricarticle and the remaining or residual silicone solvent may be distilledand recovered, which thereby deposits at least a portion of the sizingagent on the fabric article to provide a treated fabric article. Forexample, according to an embodiment, a bulk portion of the fabrictreatment composition is drained from the drycleaning appliance to aholding tank or distillation unit after the desired contacting duration.Afterwards, the treated fabric article may be subjected to centrifugalforce to extract another portion of the remaining fabric treatmentcomposition from the treated fabric article. Removal of the volatilesilicone solvent by evaporation thereby deposits the sizing agentcontained therein on to the fabric article.

In view thereof, similar to other conventional dry cleaning sizingproducts, the sizing effects are determined by the amount of sizingagent retained on the fabric article after removal of the siliconesolvent and any subsequent extraction rinses. Accordingly, the sizingeffect depends on a number of factors such as the rate of distillation,the concentration of the sizing agent in the fabric treatmentcomposition, and the extraction force.

Suitable sizing agents are based on rosin acids (C₂₀H₃₀O₂), which arecomponents of tall oil. Tall oil is a dark odorous liquid that is acommon by-product of a paper making process from wood pulp derived fromconiferous trees, such as pine trees. Abietic acid (which is also knownas abietinic acid or sylvic acid) is the most abundant of severalclosely-related organic acids that constitute most of the rosin.Further, this wood-based rosin may also include, for example, pimaricacid, palustric acid, isopimaric acid, dehydroabietic acid, neoabieticacid and other resins and neutrals. For example, the wood-based rosinmay include 40-46% abietic acid, 3-7% pimaric acid, 4-8% palustric acid,11-15% isopimaric acid, 8-12% dehydroabietic acid, 3-5% neoabietic acidand 6-8% other resins and 10-14% neutrals, wherein the percentages arebased on a weight percent of the total composition.

Accordingly, the sizing agents of embodiments of the invention arederived from rosin acids, such as abietic acid, which have beenhydrogenated and esterified, and are thus, hydrogenated rosin esters.After hydrogenation, the mixture may include predominantlydihydroabietic acid and tetrahydroabietic acid, with some dehydroabieticacid and lesser amounts of other rosin acids. As such, sizing agents ofembodiments of the invention include hydrogenated rosin esters of ahydrogenated wood rosin. Hydrogenated rosin has greater resistance tooxidation than its non-hydrogenated variant, has less odor, less taste,and higher stability to light. Foral® AX synthetic resin, which ishydrogenated wood rosin and is commercially available from Pinova, Inc.(Brunswick, Ga.), is a suitable precursor for the sizing agentsdisclosed herein.

According to one embodiment of the invention, the hydrogenated rosinester is a polyol ester of a hydrogenated rosin acid, which may bederived from polyols such as diols, triols, tetraols and the like.Exemplary diol esters include a diol moiety such as triethylene glycolor the like. Other exemplary polyol esters may include other polyolmoieties, such as glycerol, pentaerythritol, or the like. The polyolmoiety, which affects the softening point and the solubility of thehydrogenated rosin ester, may be modified accordingly. Exemplarycommercially available hydrogenated rosin esters include products thatare available from Pinova, Inc. (Brunswick, Ga.) under the tradenamesForal® 85, Foral® 105, and Foral® 3085. These resins, a priori, wouldseem not to be soluble in silicone solvents due to their chemicalcomposition, but show remarkable solubility in various silicone drycleaning solvents and provide unexpected sizing properties.

Typical compositions for the Foral® hydrogenated rosin esters areprovided below. These are typical values, but compositions may varyoutside these ranges. Foral® 85 glycerol ester of hydrogenated rosinincludes free resin acids=3-5%; mono-ester=1-3%; di-ester=20-30%;tri-ester=55-65%; and neutrals and other components=5-10%. Foral® 105pentaerythritol ester of hydrogenated rosin: free resin acids=4-9%;mono-ester=1-3%; di-ester=5-10%; tri-ester=35-45%; tetra-ester=40-50%;neutrals and other components=5-10%, wherein the percentages are basedon a weight percent of the total composition.

Compounds suitable as the silicone solvent include volatile siloxaneshaving linear, branched, or cyclic structures. Volatile siloxanesolvents generally contain a polysiloxane structure that includes from 2to 20 silicon atoms and have, for example, a boiling of below about 300°C. point at a pressure of 760 millimeters of mercury (“mm Hg”).Exemplary linear or branched, volatile siloxane include, but are notlimited to, one or more of hexamethyldisiloxane, octamethyltrisiloxane,decamethyltetrasiloxane, dodecamethylpentasiloxane,tetradecamethylhexasiloxane, hexadecamethylheptasiloxane ormethyltris(trimethylsiloxy)silane. Exemplary cyclic siloxane solvents,include but are not limited to, octamethylcyclotetrasiloxane,decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane,tetradecamethylcyclohepta-siloxane. According to one embodiment,decamethylcyclopentasiloxane is used as the dry cleaning medium.

It is advantageous to provide the sizing agent as a concentrated productwhich may be added to bulk quantities of the dry cleaning medium.Accordingly, other additives, such as co-solvents and dispersing aids,may be included in the fabric treatment composition to provide aconcentrate that readily disperses and mixes into the bulk dry cleaningmedium of silicone solvent.

Suitable co-solvents include those solvents that do not causedeleterious effects to the fabric article or the dry cleaning equipment,and do not produce unacceptable odors. For safety, the co-solvent mayadvantageously have a flash point near or greater than of the volatilesiloxane solvent, such as 170° C. or greater. Exemplary co-solventsinclude, but are not limited to, dipropylene glycol monomethyl ether,dipropylene glycol monobutyl ether, dipropylene glycol monoethylacetate, dipropylene glycol monopropyl acetate, dipropylene glycolmonobutyl acetate, diethylene glycol monomethyl ether, diethylene glycolmonobutyl ether, diethylene glycol monoethyl acetate, diethylene glycolmonopropyl acetate, or diethylene glycol monobutyl acetate, and thelike. According to one example, the co-solvent is dipropylene glycolmonomethyl ether.

Suitable dispersing agents include various distilled petroleum products,such as light mixture of alkanes in the C15 to C40 range. Exemplarydispersing aids include, but are not limited to mineral oils, such aswhite mineral oil. According to one example, the dispersing agent iswhite mineral oil 70 USP, which is a medium viscosity white mineral oiland is commercially available from Ashland Chemical Company.

Suitable fabrics articles useful in practicing embodiments of thepresent invention include those articles comprising natural fibers.Non-limiting examples of natural fibers include wool, cotton, silk, andflax. Other suitable fabric articles include those articles comprisingnatural and synthetic fibers. Non-limiting examples of synthetic fibersinclude, polyesters, nylons, polyacrylics, and polyolefins.

According to various embodiments of the invention, a concentratedmixture of the fabric treatment composition includes about 25 wt % toabout 45 wt % of the hydrogenated rosin ester; about 25 wt % to about 35wt % of the silicone solvent; about 2 wt % to about 15 wt % of thedispersing agent; and about 25 wt % to about 35 wt % of the co-solvent,wherein the weight percent is based on the total weight of theconcentrated mixture. For example, the fabric treatment compositionconcentrate may include about 35 wt % of the hydrogenated rosin ester,about 30 wt % of the silicone solvent, about 5% of the dispersing agent,and about 30 wt % of the co-solvent. In one example, the fabrictreatment composition concentrate includes about 35 wt % of Foral® 85resin, about 30 wt % of decamethylcyclopenta-siloxane, about 5% of whitemineral oil, and about 30 wt % of dipropyleneglycol monomethyl ether.

The fabric treatment composition concentrate may be diluted with one ormore non-aqueous dry cleaning solvents, such as a siloxane solvent toform an operative mixture of the fabric treatment composition. As usedherein, the operative mixture of the fabric treatment composition arethose compositions that are used to contact the sizing agent and thefabric article. Accordingly, the operative mixture of the fabrictreatment composition may include about 0.1 wt % to about 5 wt % of thehydrogenated rosin ester, wherein the weight percent is based on thetotal weight of the operative mixture. For example, the wt % of thehydrogenated rosin ester may be within the range from about 0.2 wt % toabout 5 wt %; from about 0.3 wt % to about 3 wt %; from about 0.4 wt %to about 2 wt %; or about 0.5 to about 2 wt % based on the total weightof the operative mixture. According to one embodiment, the operativemixture of the fabric treatment composition is about 0.5 wt % to about 3wt % of a fabric treatment composition concentrate having about 25 wt %to about 45 wt % of the hydrogenated rosin ester; about 25 wt % to about35 wt % of the silicone solvent; about 2 wt % to about 15 wt % of thedispersing agent; and about 25 wt % to about 35 wt % of the co-solvent,wherein the weight percent is based on the total weight of theconcentrated mixture.

The embodiments of the invention are illustrated by the followingexamples that are not to be regarded as limiting the scope of theinvention or the manner in which it can be practiced.

EXPERIMENTAL

Drape Stiffness: The “drape stiffness” test measures the resistance tobending of a material. The sizing properties of the resins of thisinvention were determined via measuring flexural rigidity (stiffness)using DRAPE-FLEX Stiffness Devise made by Fabric Development Testslocated in Brooklyn, N.Y. Strips (2.5×15 centimeters) of un-sized 100%cotton are treated with solutions of the resins at variousconcentrations. The test strips are cut in both fabric width and lengthsand the results of each pair are averaged. The drape or stiffness of thetest strips is determined by the test strip breaking at a 45 degreeplane from horizontal. The results are measured in centimeters at the 45degree break. The higher the number, the more fabric stiffness or bodyor hand that was imparted to the test fabric. The strips were soaked insolvent solutions (0, 1, 2, or 3% by weight in PERC) containing the testresins for ten minutes, drained and air dried. The dried strips werethen pressed to remove any inadvertent wrinkles. The strips are thenplaced on the DRAPE-FLEX tester and measured.

Example 1

α-Pinene/β-Pinene copolymer; 0% (4.4 cm); 1% (6.8 cm); 2% (8.2 cm); and3% (9.3 cm).

Example 2

Rosin Ester Resin 1 (Foral® 85 from Pinova, Inc. (Brunswick, Ga.)): 0%(4.4 cm); 1% (7.1 cm); 2% (9.0 cm); and 3% (9.6 cm).

Example 3

Rosin Ester Resin 2 (Foral® 105 from Pinova, Inc. (Brunswick, Ga.)): 0%(4.4 cm); 1% (6.5 cm); 2% (9.1 cm); and 3% (9.8 cm).

Example 4

Rosin Ester Resin 3 (Foral® 3085 from Pinova, Inc. (Brunswick, Ga.)): 0%(4.4 cm); 1% (6.7 cm); 2% (7.7 cm); and 3% (9.9 cm).

The foregoing results demonstrate that the rosin ester resins 1-3provide comparable sizing characteristics to that of a known sizingagent, i.e., α-pinene/β-pinene copolymer.

Example 5 Test Product Batch

Dipropyleneglycol monomethyl ether, 900 pounds (30 wt %); Ge siliconePPP-SB 32, 900 pounds (30 wt %); white mineral oil, 50 pounds (5 wt %);and Pinova® Foral® 85 Resin, 1,150 pounds (35 wt %).

1 inch×8 inch 100% cotton fabric pieces were tested usingdecamethylcyclopenta-siloxane as the dry cleaning fluid. The swatcheswere cut from fabric in both the length and width (woof/weft and fill)directions. The swatches were soaked in 0, 1 and 3 wt % concentrationsof the test product batch in silicone dry cleaning solvent for 10minutes. The swatches were air dried, oven dried at 75° C. for at least30 minutes and conditioned, and finally ironed to remove wrinkles priorto testing. The stiffness of swatches was tested three times via theDrape Flex Tester, and the width and length fabric test strip resultswere averaged; the higher the number the more rigid the fabric.

TABLE 1 Flex test results using test product batch of Foral ® 85 resin.Sizing Concentration 0% 1.0% 2.0% Length (cm) 4.5 4.6 6.2 Width (cm) 3.63.9 4.7 Total (cm) 8.1 8.5 10.9

The benefits of using sizing products in dry cleaning are considerable.Sizing enhances the wear ability, drape and feel of garments thatrequire dry cleaning. Garments contain finishes that are removed duringthe dry cleaning process leaving the fabric limp, lifeless and often outof shape. Finishing garments is made more difficult. Adding sizingduring the dry cleaning adds body, enhanced feel to the fabrics and thefinished garments retain their shape longer.

The sizing agents of embodiment of the invention enhance the hand of thedry cleaned garment, aids in finishing, and enhances fabric appearance.It was noted that tailored garments such as suits have a luxuriousbrighter appearance. Unexpectedly, it was observed that dark wools donot attract or hold lint.

One manner of using the fabric treatment concentrate is to introduce itinto the machine via injection controls of a standard dry cleaning unit.This allows the operator to select the specific loads of fabric articlesto receive the sizing agent treatment. One manner of treating fabricarticles is to inject a detergent, which is used to “clean” thearticles, and then introduce the sizing agent at a different time thanthat for introducing the detergent.

Normally most dry cleaning units are made with two separate solventtanks; a clean tank containing new or distilled solvent and a work tankcontaining solvent with detergent and additives which is used to cleanthe garments and/or articles. In practice, operators of dry cleaningunits add makeup solvent (new/distilled or reclaimed solvent based onpounds cleaned) with any detergent or additives once a day in order tomaintain the target “Charge”.

For example, an old method of adding detergent and other additives todry cleaning cleaning machines still in use today is the “ChargeMethod”. Essentially it involves mixing and dissolving theadditive/product in the dry cleaning solvent at a specificconcentration. In practice the “Charge” is typically in the 0.5 to 1.0vol % range. For example, for a 1 vol % charge for every 10 gallons ofsolvent in the dry cleaning units work tank 13 fluid ounces of additiveis added to the solvent and mixed inside the wash wheel of the drycleaning unit. The 1 vol % charge is maintained by adding detergent orsizing additives every time clean or distilled solvent is added to theworking tank.

Accordingly, five ounces of the test product described above wasinjected on every load into a 35 pound dry cleaning unit containingsilicone fluid dry cleaning solvent via a programmable peristalticinjection devise. The cleaned garments exhibited an improved hand orfeel. The garments were luxurious in appearance, had better drape, andhad a pronounced firmer body. For example, a cotton Khaki pair of slackswas included in load of garments cleaned in silicone solvent containingthe above sizing product. An identical pair of cotton Khaki slacks wascleaned via a home laundry machine using a convectional laundrydetergent. The two slacks were presented to a panel of five (5) peoplewho observed the slacks and in a blind test felt the slacks. Allobserved a difference in appearance and in fabric hand/feel between thetwo pair of slacks. The garment dry cleaned in the presence of the abovesizing agent was universally declared to have enhanced appearance andfabric body/hand and was judged to be superior to the garment that waslaundered.

As used herein and in the appended claims, the singular forms “a”, “an”,and the include plural reference unless the context clearly dictatesotherwise. As well, the terms “a” (or “an”), “one or more” and “at leastone” can be used interchangeably herein. It is also to be noted that theterms “comprising”, “including”, “characterized by” and “having” can beused interchangeably.

While the invention has been illustrated by the description of one ormore embodiments thereof, and while the embodiments have been describedin considerable detail, they are not intended to restrict or in any waylimit the scope of the appended claims to such detail. Additionaladvantages and modifications will readily appear to those skilled in theart. The invention in its broader aspects is therefore not limited tothe specific details, representative product and/or method and examplesshown and described. The various features of exemplary embodimentsdescribed herein may be used in any combination. Accordingly, departuresmay be made from such details without departing from the scope of thegeneral inventive concept.

What we claim are:
 1. A method for applying a fabric treatmentcomposition to a fabric article in a dry cleaning appliance having atreatment chamber, said method comprising the steps of: (a) dispensing afabric treatment composition into the treatment chamber, wherein thefabric treatment composition includes a sizing agent comprising ahydrogenated rosin ester, and a silicone solvent; and (b) contacting thefabric article with the fabric treatment composition.
 2. The method ofclaim 1, wherein the hydrogenated rosin ester is a polyol ester of ahydrogenated rosin acid.
 3. The method of claim 2, wherein the polyolester comprises a polyol moiety selected from the group consisting ofglycerol, pentaerythritol, and triethylene glycol.
 4. The method ofclaim 1, wherein the hydrogenated rosin ester comprises a hydrogenatedwood rosin.
 5. The method of claim 1, wherein the fabric treatmentcomposition further comprises: a dispersing agent; and a co-solvent. 6.The method of claim 1, wherein an operative mixture of the fabrictreatment composition comprises about 0.1 wt % to about 5 wt % of thesizing agent, wherein the weight percent is based on the total weight ofthe operative mixture.
 7. The method of claim 6, wherein the operativemixture of the composition comprises about 0.2 wt % to about 2 wt % ofthe sizing agent.
 8. The method of claim 1 further comprising: (c)providing a concentrated mixture of the fabric treatment composition,the composition comprising about 25 wt % to about 45 wt % of the sizingagent; about 25 wt % to about 35 wt % of the silicone solvent; about 2wt % to about 15 wt % of a dispersing agent; and about 25 wt % to about35 wt % of a co-solvent, wherein the weight percent is based on thetotal weight of the concentrated mixture.
 9. The method of claim 8further comprising: (d) diluting the concentrated mixture with anadditional amount of the silicone solvent to form an operative mixtureof the fabric treatment composition.
 10. The method of claim 1, furthercomprising: (e) placing the fabric article into the drying cleaningappliance; and (f) evaporating at least a portion of the siliconesolvent after the contacting step (b) to thereby provide the fabricarticle with at least a portion of the sizing agent retained thereon.